초록 ▼

Provided are filtration matrixes formed from adsorptive media, such as activated carbon, and polymeric binder for use in water filtration systems. A first aspect of the invention provides methods of making a filtration matrix comprising: mixing an adsorptive media with a polymeric binder to form a m

Provided are filtration matrixes formed from adsorptive media, such as activated carbon, and polymeric binder for use in water filtration systems. A first aspect of the invention provides methods of making a filtration matrix comprising: mixing an adsorptive media with a polymeric binder to form a mixture; impulse filling a mold with the mixture; and processing the mixture to form the filtration matrix. Filtration matrixes formed from this method are also provided. Another aspect includes methods of making a filtration matrix comprising: mixing adsorptive media with a polymeric binder to form a mixture; filling a mold with the mixture; and applying heat and pressure the mixture to form the filtration matrix, wherein the step of applying pressure to the mixture comprises compressing the mixture until a desired final shape of the filtration matrix is obtained.

대표청구항 ▼

1. A method of making a filtration matrix comprising: mixing an adsorptive media with a polymeric binder to form a mixture, the adsorptive media comprising activated carbon suitable for the removal of contaminants from water;impulse filling a mold with the mixture to an uncompressed density, impulse

1. A method of making a filtration matrix comprising: mixing an adsorptive media with a polymeric binder to form a mixture, the adsorptive media comprising activated carbon suitable for the removal of contaminants from water;impulse filling a mold with the mixture to an uncompressed density, impulse filling comprises administering impulses at a rate in the range of 6 to 120 impulses per minute; andfollowing impulse filling, heating and compressing the mixture to form the filtration matrix with a VOC capacity according to NSF-53 of 20 gal/in3 or greater. 2. The method of claim 1, wherein the rate is about 20 impulses per minute. 3. The method of claim 1, wherein the mixture has a maximum uncompressed density, and the mixture after the mold is filled is at least 90% of the maximum uncompressed density. 4. The method of claim 3, wherein the mixture after the mold is filled is at least 95% of the maximum uncompressed density. 5. The method of claim 1, wherein heating comprises heating the mold to a temperature in the range of 160° C. to 250° C. 6. The method of claim 1, further comprising providing a mold that is tapered to facilitate removal of the filtration matrix from the mold. 7. The method of claim 1, wherein the adsorptive media further comprises a lead-removal media. 8. The method of claim 1, wherein the binder comprises ultra high molecular weight polyethylene. 9. The method of claim 1, wherein the impulse filling is used to fill a plurality of molds, and wherein a plurality of filtration matrixes is formed. 10. The method of claim 9, wherein a standard deviation of the average weight of the plurality of filtration matrixes is no greater than 10% of the average weight. 11. The method of claim 10, wherein the standard deviation is no greater than 5% of the average weight. 12. The method of claim 1, wherein heating and compressing are done substantially simultaneously. 13. The method of claim 1, wherein heating occurs before compressing. 14. The method of claim 1, wherein compressing occurs before heating. 15. The method of claim 1, wherein compressing comprises applying compressive force axially to the mixture. 16. The method of claim 1, wherein the impulse filling comprises an indirect force on the mold such that the table to which the mold is secured receives a force directly. 17. A method of making a filtration matrix comprising: mixing an adsorptive media with ultra high molecular weight polyethylene to form a mixture comprising the adsorptive media in an amount in the range of 65 to 90% by weight and ultra high molecular weight polyethylene in an amount in the range of 35 to 10% by weight, the adsorptive media comprising an activated carbon suitable for the removal of contaminants from water;impulse filling a mold with the mixture to an uncompressed density, impulse filling comprises administering impulses at a rate in the range of 6 to 120 impulses per minute;following impulse filling, heating the mold to a temperature in the range of 160° C. to 200° C.;compressing the mixture until a fixed length of the filtration matrix is obtained; andcooling the mold;wherein the filtration matrix has a VOC capacity according to NSF-53 of 20 gal/in3 or greater. 18. The method of claim 17, wherein the impulse filling comprises an indirect force on the mold such that the table to which the mold is secured receives a force directly.